A non-road vehicle battery pack BDU controller

Abstract

This utility model discloses a battery pack (BDU) controller for off-road vehicles, comprising a housing and a cover, the two forming an internal cavity. The cavity is divided into a first mounting area, a second mounting area, a third mounting area, and a fourth mounting area corresponding to the four corners of the housing. The first mounting area contains a positive discharge relay, a positive charging relay, a heating relay, a positive output terminal block, and a positive charging terminal block. The second mounting area contains a pre-charge resistor, a pre-charge relay, a DC relay, and a positive input terminal block. The third mounting area contains a shunt, a fuse, and a negative input terminal block. The fourth mounting area contains a negative relay and a negative output terminal block. A fifth mounting area is located on one side wall of the housing adjacent to the third and fourth mounting areas, containing high-voltage and low-voltage connectors. This controller features a rational layout of electrical components, efficient space utilization, a small overall size, applicability to multiple battery systems, and a simple assembly process.

Description

Technical Field

[0001] This utility model belongs to the field of non-road vehicle battery pack applications, specifically relating to a non-road vehicle battery pack BDU controller. Background Technology

[0002] The BDU controller, or battery pack circuit breaker unit, is designed specifically for the inside of a battery pack and is also a type of high-voltage distribution box. It includes components such as the system main circuit relay, pre-charge relay, and current sensor, and is responsible for the current control and protection of the battery pack.

[0003] With increasing environmental awareness and the pursuit of improved working environments, reduced operating costs, and enhanced performance and safety, electric forklifts and construction machinery are being used more and more widely in the market. Most existing BDU controllers consist of an upper cover, a lower cover, copper busbars, and corresponding functional electrical components, integrating all parts into a single housing. However, this existing layout has the following shortcomings:

[0004] 1) The internal relays, shunts, pre-charge resistors, and fuses are scattered and occupy a lot of space;

[0005] 2) The copper busbars and control harnesses of each circuit are messy and disorganized, resulting in wasted resources;

[0006] 3) A dedicated sheet metal electrical board needs to be designed, increasing the total weight of the battery pack;

[0007] 4) The assembly process involves many steps and has poor insulation performance, which may even lead to safety problems. Utility Model Content

[0008] To overcome the shortcomings of existing technologies, this utility model provides a non-road vehicle battery pack BDU controller, which occupies a small area, has a low cost, high space utilization, and is easy to use.

[0009] A non-road vehicle battery pack (BDU) controller includes a housing and a cover, both forming an internal cavity. The cavity is divided into a first mounting area, a second mounting area, a third mounting area, and a fourth mounting area corresponding to the four corners of the housing. The first mounting area contains, in sequence, a positive discharge relay, a positive charging relay, a heating relay, a positive output terminal block, and a positive charging terminal block. The second mounting area contains a pre-charge resistor, a pre-charge relay, a DC relay, and a positive input terminal block. The third mounting area contains a shunt, a fuse, and a negative input terminal block. The fourth mounting area contains a negative relay and a negative output terminal block. A fifth mounting area is located on one side wall of the housing adjacent to the third and fourth mounting areas, containing high-voltage and low-voltage connectors. The interfaces of the positive output terminal block, the positive charging terminal block, and the negative output terminal block are located on the same side wall of the housing, as are the interfaces of the positive input terminal block and the negative input terminal block.

[0010] Furthermore, the box body is embedded with several mounting posts, and copper nuts are embedded in the mounting posts to cooperate in installing various circuit components and the box cover.

[0011] Furthermore, the positive output terminal block is connected to the positive discharge relay and the side wall of the housing, and includes two positive output interfaces. The positive output terminal block is also connected to a pre-charge relay, a pre-charge resistor and a DC relay via flexible wires.

[0012] Furthermore, the positive charging terminal block is connected to the positive charging relay and the side wall of the housing, and includes a positive charging interface.

[0013] Furthermore, the positive input terminal block is connected to the positive charging relay, the positive discharging relay, the pre-charging resistor, and the side wall of the housing, and includes two positive input interfaces.

[0014] Furthermore, the negative input terminal block connects the shunt and the side wall of the housing, and includes two negative input interfaces.

[0015] Furthermore, the negative output terminal block is connected to the negative relay and the side wall of the housing, and includes three negative output interfaces.

[0016] Furthermore, the housing includes a DC circuit, a heating circuit, and a pre-charge circuit. The DC circuit is connected in series with the DC relay and the fuse; the heating circuit is connected in series with the heating relay; and the pre-charge circuit is connected in series with the pre-charge resistor and the pre-charge relay.

[0017] Furthermore, the positive output terminal block, positive charging terminal block, positive input terminal block, negative input terminal block, and negative output terminal block are all hard copper busbars.

[0018] Compared with the prior art, the present invention has the following advantages:

[0019] (1) The electrical components inside the box of this application are arranged in a reasonable manner, the space is used efficiently, the overall volume is small, and it is suitable for a wide range of battery systems; the input and output positions are placed in the four corners of the shell, which makes it convenient to connect copper busbars, aluminum busbars or wire harnesses from different positions and directions.

[0020] (2) This application adopts a novel plug-in connection method, combined with a high-precision positioning structure and locking device to ensure the reliability and stability of electrical connection; the copper nuts embedded in the box are used to assemble various circuit components and the box cover, and the fixed position is safe and reliable. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the BDU controller of this utility model;

[0022] Figure 2 This is a schematic diagram of the box structure of this utility model;

[0023] Figure 3 This is a schematic diagram of the internal components of this utility model (without copper busbars).

[0024] Figure 4 This is a schematic diagram of the internal components (including copper busbars) of this utility model.

[0025] Figure 5 This is the circuit schematic diagram of the controller of this utility model.

[0026] In the diagram: 10-Box body, 11-First mounting area, 12-Second mounting area, 13-Third mounting area, 14-Fourth mounting area, 15-Fifth mounting area, 20-Box cover, 31-Positive discharge relay, 32-Positive charging relay, 33-Heating relay, 34-Pre-charge resistor, 35-Pre-charge relay, 36-DC relay, 37-Shunt, 38-Fuse, 39-Negative relay, 41-Positive output terminal block, 42-Positive charging terminal block, 43-Positive input terminal block, 44-Negative input terminal block, 45-Negative output terminal block, 51-High voltage connector, 52-Low voltage connector, 60-Mounting post. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0028] like Figures 1-5As shown, a non-road vehicle battery pack (BDU) controller includes a housing 10 and a cover 20, which together form a receiving cavity. The receiving cavity is divided into a first mounting area 11, a second mounting area 12, a third mounting area 13, and a fourth mounting area 14 corresponding to the four corners of the housing 10. The first mounting area 11 contains a positive discharge relay 31, a positive charging relay 32, a heating relay 33, a positive output terminal block 41, and a positive charging terminal block 42, arranged sequentially. The second mounting area 12 contains a pre-charge resistor 34, a pre-charge relay 35, a DC relay 36, and a positive input terminal block 43. The third... The fourth installation area 13 houses a shunt 37, a fuse 38, and a negative input terminal block 44; the fifth installation area 14 houses a negative relay 39 and a negative output terminal block 45; a fifth installation area 15 is located on one side wall of the housing 10 adjacent to the third and fourth installation areas 13 and 14, and a high-voltage connector 51 and a low-voltage connector 52 are located in the fifth installation area 15; the interfaces of the positive output terminal block 41, the positive charging terminal block 42, and the negative output terminal block 45 are located on the same side wall of the housing 10, and the interfaces of the positive input terminal block 43 and the negative input terminal block 44 are located on the same side wall of the housing 10. All four terminals—positive output terminal block 41, positive charging terminal block 42, positive input terminal block 43, negative input terminal block 44, and negative output terminal block 45—are made of hard copper.

[0029] It can be understood that the internal components within the cavity include: two positive high-current relays (i.e., positive discharge relay 31 and positive charge relay 32, used for positive charge and discharge, respectively, controlling the on / off state of the circuit), one negative high-current relay (i.e., negative relay 39, used for negative charge and discharge, controlling the on / off state of the circuit), three low-current relays (i.e., DC relay 36, heating relay 33, and pre-charge relay 35, used for DC, heating, and pre-charge positive sides, respectively, controlling the on / off state of the circuit), one shunt 37 (used on the negative side, monitoring the current magnitude), one fuse 38 (used on the positive side of the DC circuit, protecting the circuit), one pre-charge resistor 34 (used on the positive side of the pre-charge circuit, protecting the pre-charge circuit and realizing the pre-charge function), one high-voltage connector 51 (connected to the internal control harness, used for high-voltage signal input and output), one low-voltage connector 52 (connected to the internal control harness, used for low-voltage signal input and output), internal connecting copper busbars, wiring harnesses, and fixing bolts.

[0030] The box body 10 and the lid 20 of this application are made of high-strength, insulating, and heat-dissipating engineering plastic through injection molding. The interior has a space for accommodating electrical components, and the box body 10 and the lid 20 have heat dissipation holes. The plastic box body 10 adopts a multi-layer cavity structure to separate electrical components with different functions, effectively avoiding interference. It has high space utilization, light weight, low cost, excellent insulation performance, and excellent flame retardant and corrosion resistance.

[0031] Specifically, the positive output terminal block 41 connects the positive discharge relay 31 and the side wall of the housing 10, and includes two positive output interfaces; the positive output terminal block 41 is also connected to the pre-charge relay 35, the pre-charge resistor 34, and the DC relay 36 via flexible wires. The positive charging terminal block 42 connects the positive charging relay 32 and the side wall of the housing 10, and includes one positive charging interface. The positive input terminal block 43 connects the positive charging relay 32, the positive discharge relay 31, the pre-charge resistor 34, and the side wall of the housing 10, and includes two positive input interfaces. The negative input terminal block 44 connects the shunt 37 and the side wall of the housing 10, and includes two negative input interfaces. The negative output terminal block 45 connects the negative relay 39 and the side wall of the housing 10, and includes three negative output interfaces.

[0032] It is understandable that the internal electrical components of the housing 10 are rationally arranged, space is efficiently utilized, the overall size is small, and it is suitable for a wide range of battery systems. The input and output positions are located in the four corners of the housing, making it convenient to connect the copper plate or wiring harness from different positions. The battery positive and negative outputs of this application have three fixed positions, with two positive output positions located in one corner of the BDU, and the positive charging and discharging positions are placed separately; the three fixed positions of the negative output are integrated on the same copper busbar (saving materials), which can meet the needs of multiple battery modules (single branch), two sets in parallel (two branches), and multiple sets in parallel (multiple branches) connected to the BDU from different directions; the housing surface has injection molded integrated markings (clear markings to avoid incorrect connection).

[0033] In addition, the housing 10 includes a DC circuit, a heating circuit, and a pre-charge circuit. The DC circuit is connected in series with a DC relay 36 and a fuse 38; the heating circuit is connected in series with a heating relay 33; and the pre-charge circuit is connected in series with a pre-charge resistor 34 and a pre-charge relay 35.

[0034] The housing 10 contains several mounting posts 60, each with a copper nut for mounting various circuit components and the housing cover 20. A novel plug-in connection method, combined with a high-precision positioning structure and locking device, ensures the reliability and stability of the electrical connection. The connection parts are made of highly conductive metal and undergo anti-oxidation treatment to reduce contact resistance and minimize energy loss.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A non-road vehicle battery pack BDU controller, comprising a housing (10) and a cover (20), the interior of which forms a receiving cavity, characterized in that, The receiving cavity is divided into a first mounting area (11), a second mounting area (12), a third mounting area (13), and a fourth mounting area (14) corresponding to the four corners of the housing (10). The first mounting area (11) is provided with a positive discharge relay (31), a positive charging relay (32), a heating relay (33), a positive output terminal block (41), and a positive charging terminal block (42) in sequence. The second mounting area (12) is provided with a pre-charging resistor (34), a pre-charging relay (35), a DC relay (36), and a positive input terminal block (43). The third mounting area (13) is provided with a shunt (37), a fuse (38), and a negative output terminal block. Input terminal (44); a negative relay (39) and a negative output terminal (45) are provided in the fourth installation area (14); a fifth installation area (15) is provided in the box (10) on one side wall of the third installation area (13) and the fourth installation area (14), and a high voltage connector (51) and a low voltage connector (52) are provided in the fifth installation area (15); the interfaces of the positive output terminal (41), the positive charging terminal (42) and the negative output terminal (45) are located on the same side wall of the box (10), and the interfaces of the positive input terminal (43) and the negative input terminal (44) are located on the same side wall of the box (10).

2. The off-road vehicle battery pack BDU controller according to claim 1, characterized in that, The box body (10) is embedded with several mounting posts (60), and copper nuts are embedded in the mounting posts (60) to cooperate in installing various circuit components and the box cover (20).

3. A non-road vehicle battery pack BDU controller according to claim 1, characterized in that, The positive output terminal block (41) is connected to the positive discharge relay (31) and the side wall of the housing (10), and includes two positive output interfaces. The positive output terminal block (41) is also connected to the precharge relay (35), the precharge resistor (34) and the DC relay (36) via a flexible wire.

4. A non-road vehicle battery pack BDU controller according to claim 1, characterized in that, The positive charging terminal block (42) is connected to the positive charging relay (32) and the side wall of the housing (10), and includes a positive charging interface.

5. A non-road vehicle battery pack BDU controller according to claim 1, characterized in that, The positive input terminal block (43) is connected to the positive charging relay (32), the positive discharging relay (31), the pre-charging resistor (34), and the side wall of the housing (10), and includes two positive input interfaces.

6. A non-road vehicle battery pack BDU controller according to claim 1, characterized in that, The negative input terminal block (44) connects the shunt (37) and the side wall of the housing (10), and includes two negative input interfaces.

7. A non-road vehicle battery pack BDU controller according to claim 4, characterized in that, The negative output terminal block (45) is connected to the negative relay (39) and the side wall of the housing (10), and includes three negative output interfaces.

8. A non-road vehicle battery pack BDU controller according to any one of claims 1-7, characterized in that, The housing (10) includes a DC circuit, a heating circuit and a pre-charge circuit. The DC circuit is connected in series with the DC relay (36) and the fuse (38); the heating circuit is connected in series with the heating relay (33); and the pre-charge circuit is connected in series with the pre-charge resistor (34) and the pre-charge relay (35).

9. A non-road vehicle battery pack BDU controller according to any one of claims 1-7, characterized in that, The positive output terminal block (41), positive charging terminal block (42), positive input terminal block (43), negative input terminal block (44) and negative output terminal block (45) are all hard copper busbars.

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